Box structure



D. B. KAUFFELD Oct. 22, 1963 BOX STRUCTURE Filed Sept. 26. 1961ATTORNEYS United States Patent 3,167,339 EQX STRUCTURE Eon B. Kauifeld,Lexington, Ky., assignor to Foils Packaging Corporation, a corporationof Ohio Filed Sept. 26, 19 61, Ser. No. 146,741 11 Claims. (Cl. 229-17)This invention relates to the structure of paperboard blanks and toboxes made from said blanks, and more particularly relates to animproved box having a special top structure serving both as a closureand as a dispensing means for the contents of the box.

It is an important object of this invention to provide an improved boxfor packaging dry products, such as cereals, soap flakes, condiments,and other granular materials.

Another important object of the invention is to provide an improved boxstructure having a special pull-open tab enabling the box to be easilyopened without the use of instruments, and to provide a convenientclosure for reclosing the box to protect the contents thereof, the tabalso serving as a pouring agent during dispensing of the contents of thebox.

Still another important object of the invention is to provide in thevicinity of the pull tab a special box structure which, when the box issqueezed, forms a pouring spout and simultaneously opens the box todispense its contents, the rate of dispensing being controlled by thedegree of squeezing of the box, and said box at least partiallyreclosing when the squeezing pressure is released.

it is another object of the invention to provide a box made of materialhaving thermoplastic surfaces which can be sealed together in order toclose the box, and wherein the sealing is accomplished around aflange-like end structure which is disposed entirely externally of thebox and relatively remote from the contents thereof, whereby thecontents of the box are protected from damage by the heat applied to theend structure to accomplish the sealing thereof.

Still another object of the invention is to provide a novel endstructure which is especially strong and has particular resistance todistortion or damage of the type which might result from dropping of thebox during handling, the box also providing a seal serving to protectthe contents from contamination and/ or staleness during the shelf lifeof the product.

Other objects and advantages of the invention will become apparentduring the following discussion of the drawings, wherein:

FIG. 1 is a plan view of a blank suitable for making the body portion ofthe box according to the present invention, cut lines being shown inthis figure as solid lines, and embossed bend lines being shown asdashed lines;

FIG. 2 is a plan view of an end closure blank for a box according to thepresent invention, the cut lines and embossed bend lines being shownsimilarly as in FIG. 1;

PEG. 3 is a perspective view of the body of a box formed by bending theblank of FIG. 1 about a plurality of longitudinal bend lines and sealingthe adjacent side panels together along a longitudinal seam tab in orderto provide a hollow polygonal body;

FIG. 4 is a perspective view of a box body similar to that shown in FIG.3 but showing an end panel inserted in the body;

FIG. 5 is a perspective view of a finished container formed by bendingthe end flaps of the body over the flange flaps of the end panel andsealing the resulting structure together;

FIG. 6 is a perspective view of a box similar to that shown in FIG. 5,but showing the box partially opened 2 by pulling a pull tab away fromthe box to break its seal with a flange flap of the end panel;

FIG. 7 is a perspective view of a box similar to FIG. 6 but showing thesides of the box squeezed toward each other to effect opening of the boxin the vicinity of the pull tab and to bend the pull tab to form adispensing spout; and 7 FIG. 8 is an enlarged cross-sectional viewshowing one form of laminated material from which the blank and the boxshown in the other figures may advantageously be made.

Referring now to FIG. 1, the top blank includes four side panels 21, 31,41 and 51, these panels being arranged side by side and mutuallyseparated by four longitudinal embossed bend lines 22, 32, 42 and 52,these bend lines extending the full length of the blank. To the left ofthe bend line 22 is a side seam tab 11, this tab being bent at rightangles to the side panel 21 along the bend line'22 and sealed to theinside surface of the rightmost side panel 51, as illustrated in FIG. 3wherein the blank of FIG. 1 has been set up and seamed to form a hollowpolygonal box body.

This blank is further provided with a transverse embossed crease linewhich includes the crease lines 23, 33, 43 and 53, and which creaselines divide the blank longitudinally into side panels 21, 31, 41 and 51and into end flaps 24, 34, 44 and 54. These end flaps are mutuallyseparated by intervening slits 25, 35 and 4-5 so that the end flaps maybe bent about said crease lines separately from each other for thepurpose hereinafter stated.

Referring to FIG. 2, this figure shows an end closure blank 2 having anend panel 61 which includes on its longer sides two flanges flaps 62 and63 and on its shorter sides two flange flaps 64 and 65, the latter flapbeing divided in half by a cut line 66. These flange flaps arerespectively joined to the end panel 61 by embossed crease lines 62a,63a, 64a and 65a, and the ends of the longer flange flaps 62 and 63 areseparated from the shorter flange flaps by slits 62b and 63b for thepurpose to be hereinafter stated.

When the body blank shown in FIG. 1 has been set up to form a hollowpolygonal body as shown in FIG. 3 in which the seam tab 11 has beensecured to the inside surface of the panel 51, an end closure means isthen set in place as shown in FIG. 4 by bending the flange flaps 62, 63,64 and 65 to face outwardly 'of the box and lapping the four smallcorner tabs 64c and 65c over the adjacent longer tabs 62 and 63, theoutermost edges of the flange flaps 62, 63, 64 and 65 lyingsubstantially even with the position of the transverse crease lines 23,33, 43 and 53 of the body blank 1, as shown in FIG. 4. The box is thencompleted by bending the end flaps 24, 34', 44 and 54 through almostdegrees inwardly of the box so as to cover the flange flaps 62, 63, 64and 65 of the end blank 2.

In this position, if the container has thermoplastic surfaces, the sidepanel and the flange flap and the end flap are then clamped together andheated so as to fuse these plastic surfaces together. For example inFIG. 5, pressurewould be applied outside of the container near the endthereof in the vicinity of the arrow R and pressure would also beapplied from the inside in the vicinity of the arrow R thereby squeezingtogether the side, panel 21, the flange flap 63 and the end flap 24, and

sealing these portions together. This same procedure applies to thestructure on the other three sides at the end of the box.

By reference to FIGS. 1 and 6 it will be seen that the separated fromthe inner portion of the end flap 54- by an embossed crease line 57.

In addition, a longitudinally disposed embossed bend line 58 is providedwhich bisects the end portion of the side panel 51, the end flap 54 andthe pull tab 56. This tab also includes a concave arcuate outer edge 59which, as can be best seen in FIG. 7, provides an improved pouring spoutwhen the 'box is squeezed as shown by the hand H gripping the end of thebox and causing it to bend as shown in FIG. 7, the squeezing pressurebeing applied in the direction of the arrows AA.

When the closed box shown in FIG. is to be opened, the consumer graspsthe pull tab 56 and pulls it outwardly into the position shown in FIG. 6until it lies substantially in the same plane as the side panel 51.Then, when the sides of the box are squeezed toward each other byapplication of pressure in the vicinity of the arrows A-A the end panel61 tends to break and warp inwardly about a longitudinal bend line 68,and the two halves of the flange flap 65 lap over each other therebyretracting the end panel inwardly of the box and permitting the two sidepanels 21 and 41 to approach each other. As these two panels approacheach other, the body panel 52 bends along the bend line 58 and bendsdownwardly so as to form a trough-shaped pouring spout beneath anopening created by retreating of the body panel 51 away from the flangeflap 65. The contents of the box can therefore pass between the panel 51and the flange flap 65 at a rate controlled by the degree of squeezingpressure applied to the box, and the contents then pour outwardly alongthe trough-shaped spout including the end flap 54 and the pull tab 56.

When the squeezing pressure at the arrows A-A' is released, the boxtends to resume its normal shape in which-the panel 51 approaches theflange flap-s 65 thereby tending to close the box. The end flap 54 andthe pull tab 56 can also be bent back over the flange flap 65 to theposition shown in FIG. 5 so as to again close the mouth of the box.

Referring to FIG. 8, this figure illustrates a preferred laminatedmaterial, of which the present box can be made, including a paperboardcore K made of virgin or reclaimed kraft, or other suitable material,the core having plastic coatings on its surfaces. It the box is to bewelded or heat-sealed at its various seams, at least one surface shouldbe coated with a suitable thermoplastic having a melting pointsufliciently low that the core material will not be damaged at theheatsealing temperature. For instance, one or both surfaces can becoated with polyethylene P which is well adapted to heatsealingpurposes. Alternatively, as shown in FIG. 8, the kraft core K can becoated on one side with polyethylene P and on the other side with vinylV to which the polyethylene P will bond but which has a higher meltingpoint, the vinyl V being a cheaper coating material. It is not essentialto the present disclosure that the box he heat-sealed, the presentstructure having utility in connection with boxes secured together byother means, such as by glue.

I do not limit my invention to the exact form shown in the drawing, forobviously changes may be rnade therein within the scope of the followingclaims.

I claim:

l. A box comprising body panels joined together along longitudinal edgesto form a hollow polygonal body and having end flaps joining the bodypanels at transverse crease lines; and end closure means closing atleast one end of said hollow body and each including an end panel havingflange flaps therearound, the end closure means" being fitted into thebody with the flange flaps facing out wardly thereof and terminating atsaid transverse crease lines, and said end flaps being bent inwardly ofthe box to cover said flange flaps and being secured thereto, at leastone end flap being wider than the flange flap which it covers and beingdivided by a crease line into an end flap portion of the same size asthe latter flangeflap and a pull-tab portion which lies against the endpanel mor mal to said flap portion when the box is sealed.

2. In a box as set forth in claim 1, said pull-tab portion, said flapportion and the body panel thereadjacent having a longitudinallydisposed bend line bisecting their transverse dimensions, and the endpanel and flange flap being bisected along their intersection with theplane in cluding the axis of the box and said last-mentioned bend line,whereby when the box is opened and squeezed at the sides adjacent theends of said wider flap, the end panel will warp about saidintersection, and the flap portion and pull-tab portion will bend aboutsaid bend line and away from the end panel to form a pouring apertureand spout.

3. In a box as set forth in claim 2, said intersection on the end panelcomprising an embossed crease line and said intersection on saidlast-mentioned flange flap comprisin a cut line across the flap. 1

4. In a box as set forth in claim 2, the outer edge of having end flapsjoining the body panels at transverse crease lines, and end closuremeans closing at least one end of said hollow body and each including anend panel having flange flaps therearound, the end closure means beingfitted into the body with the flange flaps facing outwardly thereof andterminating at said transverse crease lines and said end closure meanshaving corner tabs lapping and joining'said flange flaps together, andsaid end flaps being bent inwardly of the box to cover said flange flapsand being secured thereto, at least one end flap being wider than theflange flap which it covers and being divided by a crease line into anend flap portion of the same size as the latter flange flap and apull-tab portion which lies against the end panel normal to said flapportion when the box is sealed.

6. A heat-sealed box made of sheet material havin thermoplasticsurfaces, comprising body panels joined together. along longitudinaledges to form a hollow polygonal body and having end flaps joining thebody panels at' transverse crease lines; and end closure means closingat least one end of said hollow body and each including an end panelhaving flange flaps .therearound, the end closure means being fittedinto the body with the flange flaps facing outwardly thereof andterminating at said transverse crease lines, and said end flaps beingbent inwardly of the box to cover said flange flaps and being heatsealedthereto, at least oneend flap being wider than the flange flap which itcovers and being divided by a crease line into an end flap portion ofthe same size as the latter flange flap and sealed thereto and apull-tab portion which lies against the end panel normal to said flapportion when the box is sealed.

7. In a box as set forth in claim 6, said pull-tab por tion, said flapportion and the body panel thereadjacent having a longitudinallydisposed bend line bisecting their:

7 transverse dimensions, and the end panel and flange flap I beingbisected along their intersection with the plane including the axis ofthe box and said last-mentioned bend line, whereby when the box isopened and squeezed at the sides adjacent the ends of said wider flap,the end panel will warp about said intersection, and the flap 'p'ortionand pull-tab portion will bend about said bend line and away from theend panel to form a pouring aperture and spout.

8." In a box as set forth in claim 7, said intersection on the end panelcomprising an embossed crease line and said intersection on saidlast-mentioned flange flap'com prising a cut line across the flap.

9. in a box as set forth in claim 7, the outer edge of the pull-tabportion being arcuate and concave, where- 5 by when the tab portion isbent about said bend line the concave arcuate edge will group thecontents of the box being poured therepast.

10. A blank for making a paperboard box body comprising more than twobody panels mutually joined together along longitudinal bend lines; endflaps joined to said body panels at transverse crease lines, at leastone of the end flaps being separated from the others by cuts extendinginwardly to said crease lines and said one flap having a pull-tabportion joining the flap at an edge parallel with its crease line andhaving a concave arcuate outer edge, and said blank having alongitudinal crease crease line bisecting the pull tab and theassociated end flap and extending part-way along the center of theassociated body panel.

11. A paperboard blank for closing the end of a hollow polygonal body,comprising an end panel having flange flaps therearound and joining thebody at embossed bend lines, the flange flaps being mutually separatedin the corners by slits which leave corner tabs each attached to oneflange flap and adapted to overlie an adjacent flange flap when theflaps are bent at right angles to the panel, and one of the flange flapsbeing bisected by a slit thereacross joining an embossed crease line onthe panel and disposed normal to the intersection bend line.

References Cited in the file of this patent UNITED STATES PATENTS2,323,505 Wilcox July 6, 1943 2,511,189 Woodward June 13, 1950 2,654,525Adorney et a1 Oct. 6, 1953 2,865,498 Ringler Dec. 23, 1958 FOREIGNPATENTS 472,474 Great Britain Sept. 20, 1937

1. A BOX COMPRISING BODY PANELS JOINED TOGETHER ALONG LONGITUDINAL EDGESTO FORM A HOLLOW POLYGONAL BODY AND HAVING END FLAPS JOINING THE BODYPANELS AT TRANSVERSE CREASE LINES; AND END CLOSURE MEANS CLOSING ATLEAST ONE END OF SAID HOLLOW BODY AND EACH INCLUDING AN END PANEL HAVINGFLANGE FLAPS THEREAROUND, THE END CLOSURE MEANS BEING FITTED INTO THEBODY WITH THE FLANGE FLAPS FACING OUTWARDLY THEREOF AND TERMINATING ATSAID TRANSVERSE CREASE LINES, AND SAID END FLAPS BEING BENT INWARDLY OFTHE BOX TO COVER SAID FLANGE FLAPS AND BEING SECURED THERETO, AT LEASTONE END FLAP BEING WIDER THAN THE FLANGE FLAP WHICH IT COVERS AND BEINGDIVIDED BY A CREASE LINE INTO AN END FLAP PORTION OF THE SAME SIZE ASTHE LATTER FLANGE FLAP AND A PULL-TAB PORTION WHICH LIES AGAINST THE ENDPANEL NORMAL TO SAID FLAP PORTION WHEN THE BOX IS SEALED.